Sensors and systems - Kistler

Sensors and systems Quality monitoring and process control in injection molding

www.kistler.com

www.kistler.com2

Kistler: the byword for advances in engine monitoring, vehicle safety and vehicle dynamics. Our products deliver data that plays a key part in developing efficient vehicles for tomorrow’s world.

Measurement technology from Kistler ensures top performance in sport diagnostics, traffic data acquisition, cutting force analysis and many other applications where absolutely reliable measurements are required despite extreme conditions.

By supporting all the stages in networked, digitalized production, Kistler’s systems maximize process efficiency and cost- effectiveness in the smart factories of the next generation.

Absolute Attention for tomorrow’s world

Kistler develops solutions for challenges in measurement technology with a portfolio that comprises sensors, electronics, systems and services. We push the frontiers of physics in fields such as emission reduction, quality control, mobility and vehicle safety: our products deliver top performance to meet the standards of tomorrow’s world, providing the ideal basis for Industry 4.0. This is how we pave the way for innovation and growth – for our customers, and with our customers.

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Contents

Focusing on process efficiency 4

Sensors 5

Connection technology 10

Systems 14

Accessories 20

Service 24

www.kistler.com4

100% quality in production – that’s the goal that all injection molders strive to achieve. The surest way to achieve zero-defect production during injection molding of plastics is by integrating quality assurance into the process. Kistler offers the technology, expertise and service you need to achieve this.

Optimized process efficiency thanks to technology from KistlerTo achieve the objective of zero defect production with maximum cost-effectiveness, Kistler focuses on cavity pressure. It is the most informative process variable, because it describes conditions immediately – while the molded part is actually being created. Sensors and systems based on cavity pressure detect whether or not a part is scrap at the earliest possible moment.

Lower QA costs for processors and OEMsProcess-integrated cavity pressure monitoring during injection molding cuts the costs of quality assurance. This cost-effective solution protects plant operators against the possibility of faulty parts reaching the customer; it also ensures that there is no disruption to any downstream assembly operations.

Focusing on process efficiency

Cavity pressure monitoring during injection molding reduces the costs of quality assurance.

Injection molding with Kistler – now online View our animation to experience convincing, first-class Kistler solutions – the sure way to achieve 100% quality in your production: www.kistler.com/injection-molding

Front diameter 1 mm 1.2 mm 2 mm 2.5 mm 2.5 mm 4 mm 6 mm

Measurands (p: pressure; T: temperature) p p+T T p p p p+T T p T p p+T T p

Technical data Type 6183D… 1) 6188A... 6193B... 1) 6184A... 6185A... 6182D... 1) 6189A... 1) 6195B... 6159A... 1) 6194B... 6157C... 1) 6190C... 1) 6192B... 6152B... 1)

Installation sketch

Measuring range

Temperature (thermocouple Type K) °C – 0 … 450 0 … 450 – – – 0 … 450 0 … 450 – 0 … 450 – 0 … 450 0 … 450 –

Pressure bar 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 – 0 ... 2,000

Sensitivity pC/bar ≈–2.25 (Unisense) ≈–4.8 – ≈–1.2 ≈–2.2 ≈–2.5 (Unisense) ≈–6.5 – ≈–2.5 – –9.4 (Unisense) ≈–9 – ≈–9.4 (Unisense)

Sensor front

machinable • – • • • • – – • – • – • •

Option: abrasion protection (not machinable) • – – • • • – – • – • – – •

Cable technology

Single wire with/without connector 2) • • – • • • • – • – • • – •

Single wire with crimp contact 3) • – – • • • – – • – • – – –

Coaxial, with standard 4)/custom cable length 5) • – – – • • – – • – • – – •

Conductive spacer sleeve • – – – • • – – • – • – – –

Compensating cable with standard 6)/custom cable length 7) – • • – – – • • – • – • • –

Exchangeable cable • at Kistler – – • • at Kistler – • – • • – •

Operating temperature

Melt temperature °C <450 <450 <450 <450 <450 <450 <450 <450 <450 <450 <450 <450 <450 <450

Mold temperature °C <200 <200 <450 <200 <200 <200 <200 <450 <200 <450 <300 <200 <450 <300

Applications + characteristics Thermoplastics

smallest front area waterproof (IP67)

Thermoplastics Thermoplastics ElastomersLSR

Thermoplastics

low overall height cable outlet 90°

Thermoplastics

insensitive to installation conditionswaterproof (IP67)

Thermoplastics

small front area waterproof (IP67)

Thermoplastics ThermoplasticsElastomersLSR

Thermoplastics

small front area

ThermoplasticsElastomersLSR

Thermoplastics Elastomers LSR

ThermoplasticsElastomers LSR


ThermoplasticsThermo-setting plasticsElastomersLSR

Accessories

Spacer sleeve Type 6464A1 8) 6464A3 8) 6464A3 8) 6470 (thrust washer) 8) 6464A1 8) 6464A1 8) 6464A3 8) 6464A3 8) 6459 6459 6459 6459 6459 6462

Minimum overall height mm 25.5 36 24.5 8.5 25.5 24 33 23 32 37 30 37 35 32

Mounting nut Type 6460A1 – – 6465 8) 6460A1 6460A1 – – 6457 8) 6457 8) 6457 8) 6457 8) 6457 8) 6453 8)

Minimum overall height mm 24 – – 11.6 24 22.5 – – 29 29 27 30 27 30

Data sheet: see www.kistler.com 003-450 6188A (000-887) 6193B (000-637) 6184A (000-600) 6185A (003-263) 003-449 6189A (000-536) 6195B (000-637) 6159A (000-032) 6194B (000-637) 6157C (003-339) 6190C (000-680) 6192B (000-637) 6152B (003-397)

Direct cavity pressure and temperature measurement – installation-compatible sensors

• Variant available – Variant not available 1) Standard product 2) Cables can be shortened by user, standard length 1.5/5 m

h = Minimum overall height, see table

Installation with spacer sleeve

Installation with mounting nut (for 6183...)

ø4 ø1

11.5

5.5

5.56.50.2 - 0.3

4.5

www.kistler.com




Installation sketch

Measuring range


Pressure bar 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 – 0 ... 2,000


Sensor front

machinable • – • • • • – – • – • – • •


Cable technology













Thermoplastics


Thermoplastics


Thermoplastics



Thermoplastics

small front area






Accessories







3) Connection to contact element 1712/1714, custom length (lmin = 0.1 m/lmax = 1.5 m) 4) l = 0.2/0.4/0.6/0.8 m 5) Custom length (lmin = 0.1 m/lmax = 5 m)

1.2

4.3

6.6

0.8

6.45

0.01

0.01

0.012

0.010

Installation with thrust washer minimum overall height, see table

ø1.2

6.4


Installation with mounting nut

ø4 ø2

Installation with mounting nut (for 6183...)

0.01

00.

010

0.01

0

0.01

00.02 ... 0.040.02 ... 0.04

0.2 - 0.3 0.2 - 0.3

2.5 2.5

5.5

5.515.5

4.5

0.75 8.

2

4.5

0.2 ... 0.04

0.2 - 0.3 0.2 - 0.35.5

5.5 4.5

0.75

8.2

4.5

2.5

2.5

0.02 ... 0.04

0.01

00.

010

0.01

0

0.01

00.02 ... 0.040.02 ... 0.04

0.2 - 0.3 0.2 - 0.3

2.5 2.5

5.5

5.515.5

4.5

0.75 8.

2

4.5

0.2 ... 0.04

0.2 - 0.3 0.2 - 0.35.5

5.5 4.5

0.75

8.2

4.5

2.5

2.5

0.02 ... 0.04

ø2.5

Seite 4/6

Temperatursensoren für Spritzgiessw

erkzeuge, Typ 6192B..., 6193B..., 6194B... und 6195B...

6192B_000-637d-12.15

©2007 ... 2015, K

istler Gruppe, Eulachstrasse 22, 8408 W

interthur, Schweiz

Tel. +41 52 224 11 11, Fax +41 52 224 14 14, [email protected]

, ww

w.kistler.com

Kistler ist eine eingetragene M

arke der Kistler H

olding AG

.

Die Inform

ationen entsprechen dem aktuellen W

issensstand. Kistler behält sich

technische Änderungen vor. D

ie Haftung für Folgeschäden aus der A

nwendung

von Kistler-Produkten ist ausgeschlossen.

Einbaubeispiele

Bild 8: Einbau Typ 6193B... mit D

istanzhülse Typ 6464A3

ø4.5

0.2 ... 0.3

9

11.5

min. 24.5

anpassenà adapterto be adjusted

+0.01

0

+0.01

0

ø1 H7 ( )

ø2,5 H7 ( )

60°

Bild 9: Einbau Typ 6195B… m

it Distanzhülse Typ 6464A

3

ø4,5

60°

0,2 ... 0,3

10

min. 23


+0,01

0ø2,5 H

7 ( )


istanzhülse Typ 6459

60°

ø5,2

min. 37

10

0,2 ... 0,3

min. ø7,2


+0,01

0ø2,5 H

7 ( )

Bild 10: Einbau Typ 6194B... mit M

ontagenippel Typ 6457

www.kistler.com




Installation sketch

Measuring range


Pressure bar 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 – 0 ... 2,000


Sensor front

machinable • – • • • • – – • – • – • •


Cable technology













Thermoplastics


Thermoplastics


Thermoplastics



Thermoplastics

small front area






Accessories






6) l = 0.4/0.8/1.2/1.6/2 m 7) Custom length (lmin = 0.15 m/lmax = 5 m) 8) Accessory delivered with product

10

ø7 ø2.5

5.2

2.5

7.2

0.2 ... 0.3

0.01

0

Installation with spacer sleeve similar to 6189A


0.01

0

0.2 - 0.3

20.5

0.75

2.5

0.02 ... 0.04

0.01

02.

5

0.2 - 0.3

5.5 4.5

4.5

0.01

0

0.02 ... 0.04

0.75

0.2 - 0.3

5.5

5.56.5

4.5

2.5

8.2


Installation with mounting nut (for 6182C and 6178A only)

ø4 ø2.5

10

Seite 4/6



6192B_000-637d-12.15

©2

00

7 ... 2

01

5, K

istler Gru

pp

e, Eulachstrasse 22, 8408 Winterthur, Schw

eizTel. +

41 52 224 11 11, Fax +41 52 224 14 14, info@

kistler.com, w

ww

.kistler.com


arke der Kistler H

olding AG

.

Die Inform





nwendung


Einb

aub

eispiele



ø4.5

0.2 ... 0.3

9

11.5

min. 24.5


+0.01

0

+0.01

0

ø1 H7 ( )

ø2.5 H7 ( )

60°



3

ø4.5

60°

0.2 ... 0.3

10

min. 23


+0.01

0ø2.5 H

7 ( )



60°

ø5.2

min. 37

10

0.2 ... 0.3

min. ø7.2


+0.01

0ø2.5 H

7 ( )



Seite 4/6



6192B_000-637d-12.15

©2007 ... 2

015, K

istler Gru

ppe, Eulachstrasse 22, 8408 W

interthur, Schweiz

Tel. +41 52 224 11 11, Fax +

41 52 224 14 14, [email protected]

, ww

w.kistler.co

mK

istler ist eine eingetragene Marke der K

istler Holding A

G.

Die Inform





nwendung


Einbau

beisp

iele



ø4.5

0.2 ... 0.3

9

11.5

min. 24.5


+0.01

0

+0.01

0

ø1 H7 ( )

ø2.5 H7 ( )

60°



3

ø4.5

60°

0.2 ... 0.3

10

min. 23


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7 ( )



60°

ø5.2

min. 37

10

0.2 ... 0.3

min. ø7.2


+0.01

0ø2.5 H

7 ( )



Seite 4/6



6192B_000-637d-12.15

©2007 ... 2

015, K

istler Gru

ppe, Eulachstrasse 22, 8408 W

interthur, Schweiz

Tel. +41 52 224 11 11, Fax +

41 52 224 14 14, [email protected]

, ww

w.kistler.co

mK

istler ist eine eingetragene Marke der K

istler Holding A

G.

Die Inform





nwendung


Einbau

beisp

iele



ø4.5

0.2 ... 0.3

9

11.5

min. 24.5


+0.01

0

+0.01

0

ø1 H7 ( )

ø2.5 H7 ( )

60°



3

ø4.5

60°

0.2 ... 0.3

10

min. 23


+0.01

0ø2.5 H

7 ( )



60°

ø5.2

min. 37

10

0.2 ... 0.3

min. ø7.2


+0.01

0ø2.5 H

7 ( )






Installation sketch

Measuring range


Pressure bar 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 0 ... 2,000 0 ... 2,000 – 0 ... 2,000 – 0 ... 2,000 0 ... 2,000 – 0 ... 2,000


Sensor front

machinable • – • • • • – – • – • – • •


Cable technology













Thermoplastics


Thermoplastics


Thermoplastics



Thermoplastics

small front area






Accessories






ø4

8

ø7



0.2 - 0.3

7.2

5.2

0.01

2

0.2 - 0.3

0.01

2

18.5

0.75

4

ø6ø10



0.01

2

0.2 ... 0.3

5.2 10

.2

0.01

2

0.2 ... 0.3

Seite 5/6



6192B_000-637d-12.15

©2

00

7 ... 2

01

5, K

istler Gru

pp


eizTel. +

41 52 224 11 11, Fax +41 52 224 14 14, info@

kistler.com, w

ww

.kistler.com


arke der Kistler H

olding AG

.

Die Inform





nwendung


ø5.2

min. ø7.2


+0.012

0ø4 H

7 ( )

60°

0.2 ... 0.3

8

min. 35


istanzhülse Typ 6459Bild 12: Einbau Typ 6192B... m

it Montagenippel Typ 6457

Mo

ntag

eD

ie Sensoren Typ 6192B... und 6194B... werden m

it dem M

on-tagenippel Typ 6457 (oder m

it der Distanzhülse Typ 6459) in

der Montagebohrung fixiert. D

ie Typen 6193B... und 6195B... w

erden ausschliesslich mit der D

istanzhülse Typ 6464A3 ein-

gebaut. D

ie Sensorfront bildet nach dem Einbau einen Teil der K

a-vitätsw

and. Der Sensor m

uss deshalb so eingepasst werden,

dass seine Front genau bündig ist. Den Stecker m

it der mit-

gelieferten Montageplatte (A

rt. Nr. 3.520.328) an einer ge-

schützten Stelle des Werkzeugs befestigen. D

en Deckel m

it einer Schraube der M

ontageplatte befestigen und den offenen Stecker abdecken.

Seite 5/6



6192B_000-637d-12.15

©2

00

7 ... 2

01

5, K

istler Gru

pp


eizTel. +

41 52 224 11 11, Fax +41 52 224 14 14, info@

kistler.com, w

ww

.kistler.com


arke der Kistler H

olding AG

.

Die Inform





nwendung


ø5.2

min. ø7.2


+0.012

0ø4 H

7 ( )

60°

0.2 ... 0.3

8

min. 35


istanzhülse Typ 6459Bild 12: Einbau Typ 6192B... m

it Montagenippel Typ 6457

Mo

ntag

eD

ie Sensoren Typ 6192B... und 6194B... werden m

it dem M

on-tagenippel Typ 6457 (oder m

it der Distanzhülse Typ 6459) in

der Montagebohrung fixiert. D

ie Typen 6193B... und 6195B... w

erden ausschliesslich mit der D

istanzhülse Typ 6464A3 ein-

gebaut. D

ie Sensorfront bildet nach dem Einbau einen Teil der K

a-vitätsw

and. Der Sensor m

uss deshalb so eingepasst werden,

dass seine Front genau bündig ist. Den Stecker m

it der mit-

gelieferten Montageplatte (A

rt. Nr. 3.520.328) an einer ge-

schützten Stelle des Werkzeugs befestigen. D

en Deckel m

it einer Schraube der M

ontageplatte befestigen und den offenen Stecker abdecken.

5www.kistler.com

Exact, reproducible pressure measurement values can only be obtained with reliable sensors that measure precisely. Piezoelectric sensors from Kistler are rugged and maintenance-free.

Sensors from Kistler offer virtually unlimited service lifetimes; they deliver highly linear measurement results, and they operate independently of temperature. They deliver high-precision measurements of minimal pressure variations (range up to 2,000 bar) and/or temperature changes of up to 300°C.

Cavity pressure can be determined directly, indirectly, contact- free or together with the contact temperature. Direct-measuring sensors are in contact with the melt in the cavity, and they measure the pressure without transmission pins. They can be installed in a bore with or without an adapter. On many sensors,

Sensors for every measuring task

the front can be adapted to the surface of the cavity so that no mark can be seen on the part. As an alternative, the force can be measured behind an ejector pin or measurement pin; it can then be converted into the pressure with the help of the pin diameter. This method is recommended if there is insufficient space for a direct-measuring sensor. For optical components with Class A surfaces or components on which marks are not permitted, the cavity pressure can be measured contact-free with a measuring pin: the compression of the mold steel is the basis for this method. CAD data is used to simplify positioning of the sensors in the mold.

For every injection molding process, Kistler supplies the ideal sensor – tailored to the installation conditions, the part geometry and the plastic material.

www.kistler.com6

Front diameter 2.5 mm 4 mm 6 mm 9 mm

Measurands (p: pressure; T: temperature) p p p p p p

Technical data Type 6178C... 6167A... 6165A... 6162A... 6163A... 6161A... 1)

Installation sketch

Measuring range

Temperature (thermocouple Type K) °C – – – – – –

Pressure bar 0 ... 200 0 ... 200 0 ... 200 0 … 200 0 … 1,000 –0.9 … 200

Sensitivity pC/bar ≈–12 (Unisense) ≈–16.5 ≈–4.0 ≈–18.5 ≈–3.9 ≈–18.4

Sensor surface

machinable • – – – – –

Option: abrasion protection (not machinable) – – – – – –

Cable technology

Single wire with/without connector 2) • • • • • –

Single wire with crimp contact 3) • – – – – –

Coaxial, with standard 4)/custom cable length 5) – • • • • •

Conductive spacer sleeve – • • – – –

Compensating cable with standard 6)/custom cable length 7) – – – – – –

Exchangeable cable – • • • • •


Melt temperature °C <450 <450 <450 <450 <450 <450

Mold temperature °C <200 <200 <200 <200 <200 <200

Applications + characteristics Foam injection moldingCompression moldingThermoplastics

High sensitivity

Low-viscosity materials

With diaphragm

Low-viscosity materialsSMC/transfer molding

Welded front gap

Fiber-reinforced compositesSMC/RTM

Welded front gap

Fiber-reinforced compositesHigh-pressure RTMComposites

Welded front gap


Welded front gap

Accessories

Spacer sleeve Type 6464A1 8) 6459 – 6462 6462 –

Minimum overall height mm 21 30 30 32 32 30

Mounting nut Type 6460A1 6457 8) – 6453 8) 6453 8) –

Minimum overall height mm 22.5 27 27 30 30 –

Data sheet: see www.kistler.com 6178C (003-448) 6167A (000-033) 6165A (000-033) 6162A (000-888) 6163A (000-889) 6161A (003-053)


• Variant available – Variant not available 1) Standard product 2) Cables can be shortened by user, standard length 1.5/5 m 6) l = 0.4/0.8/1.2/1.6/2 m 7) Custom length (lmin = 0.15 m/lmax = 5 m)

ø4

8

ø7



0.2 - 0.3

7.2

5.2

0.01

2

0.2 - 0.3

0.01

2

18.5

0.75

ø4 ø2.5

10

0.02 ... 0.04

0.01

02.

5

0.2 - 0.3

5.5 4.5

4.5

0.01

0

0.02 ... 0.04

0.75

0.2 - 0.3

5.5

5.56.5

4.5

2.5

8.2



(for 6182C and 6178A only)

www.kistler.com 7

Front diameter 2.5 mm 4 mm 6 mm 9 mm

Measurands (p: pressure; T: temperature) p p p p p p

Technical data Type 6178C... 6167A... 6165A... 6162A... 6163A... 6161A... 1)

Installation sketch

Measuring range

Temperature (thermocouple Type K) °C – – – – – –

Pressure bar 0 ... 200 0 ... 200 0 ... 200 0 … 200 0 … 1,000 –0.9 … 200

Sensitivity pC/bar ≈–12 (Unisense) ≈–16.5 ≈–4.0 ≈–18.5 ≈–3.9 ≈–18.4

Sensor surface

machinable • – – – – –

Option: abrasion protection (not machinable) – – – – – –

Cable technology

Single wire with/without connector 2) • • • • • –

Single wire with crimp contact 3) • – – – – –

Coaxial, with standard 4)/custom cable length 5) – • • • • •

Conductive spacer sleeve – • • – – –

Compensating cable with standard 6)/custom cable length 7) – – – – – –

Exchangeable cable – • • • • •


Melt temperature °C <450 <450 <450 <450 <450 <450

Mold temperature °C <200 <200 <200 <200 <200 <200

Applications + characteristics Foam injection moldingCompression moldingThermoplastics

High sensitivity

Low-viscosity materials

With diaphragm

Low-viscosity materialsSMC/transfer molding

Welded front gap


Welded front gap

Fiber-reinforced compositesHigh-pressure RTMComposites

Welded front gap


Welded front gap

Accessories

Spacer sleeve Type 6464A1 8) 6459 – 6462 6462 –

Minimum overall height mm 21 30 30 32 32 30

Mounting nut Type 6460A1 6457 8) – 6453 8) 6453 8) –

Minimum overall height mm 22.5 27 27 30 30 –

Data sheet: see www.kistler.com 6178C (003-448) 6167A (000-033) 6165A (000-033) 6162A (000-888) 6163A (000-889) 6161A (003-053)


3) Connection to contact element 1712/1714B, custom length (lmin = 0.1 m/lmax = 1.5 m) 4) l = 0.2/0.4/0.6/0.8 m 5) Custom length (lmin = 0.1 m/lmax = 5 m)8) Accessory delivered with product

0.01

8

0.01

5

0.4

6

ø9

24

M12

4

ø6ø10



0.01

2

0.2 ... 0.3

5.2 10

.2

0.01

2

0.2 ... 0.3

ø4

4

ø6

0.01

2

0.03

5.5

29.4

0.2

4.7

0.02

5.5

5.1

www.kistler.com8

Front diameter 3.5 mm 6 mm 12.6 mm

Technical data Type 9210A... 1) 9211B... 1) 9213B... 9204B... 1)

Installation sketch

Measuring range

Force 2) kN 0 ... 0.25 0 … 2.5 0 … 2.5 0 ... 10

Overload kN 0.3 3 3 12

Sensitivity 2) pC/N ≈–10 ≈–4.4 ≈–4.4 ≈–1.6

Cable technology

Single wire with/without connector 3) • • • •

Coaxial – • • •

Exchangeable cable – • • •

Operating temperature range °C – 40 ... 200 – 40 ... 200 – 40 ... 200 – 40 ... 200

Applications + characteristics All injection molding processes

Smallest force sensorCable output at the sideEspecially for molds with modular structure

All injection molding processes

Especially for multi- cavity molds


With M2.5 fastening thread, especially for multi-cavity and small molds


With M2.5 fastening thread

Accessories

Thrust washer Type 9406 4) 9411 4) 9413 4) –

Main installation dimensions

Dimensions mm ø 3.5 ø 6 ø 6 ø 12.6

Actual height mm 4.7 6 8.5 9.5

Minimum overall height mm 6.7 8 10.5 9.6

Data sheet: see www.kistler.com 9210A (000-601) 9211B (000-555) 9213B (000-556) 9204B (000-128)

Indirect cavity pressure measurement

4.7

ø3.5

6

ø6

9.5

ø12.6

M 2.5

8.5

ø6

M 2.5

h = Minimum overall height, see table

1) Standard product2) Conversion formula for pressure sensitivity: pressure sensitivity [pC/bar] = nominal force sensitivity [pC/N] × area of ejector pin [mm²] × 0.1 3) Cables can be shortened by the user, standard length 1.5/5 m4) Accessories delivered with product5) Elongation is proportional to the cavity pressure

4.7

3.50.010.012

0.1

0.1

+0.012

0.01

0.3

2.9

0.2

0.02

0.1

0.01

2.8

0.3

5.7

0.012

www.kistler.com 9

Longitudinal measuring pin – thread M5 M5

Technical data Type 9239A... 9247A…

Installation sketch

Measuring range

Strain 5) µε ±800 ±1,400

Overload µε ±1,000 ±2,000

Sensitivity pC/µε ≈–3.2 ≈–8.6

Cable technology

Single wire with/without connector • •

Coaxial • •

Exchangeable cable • •

Operating temperature range °C – 40 ... 200 – 40 ... 200

Applications + characteristics Optical componentsClass A surfacesSmallest design for limited installation space

Measurement of the compression of the steel caused by the cavity pressure

Optical componentsClass A surfaces

Measurement of the compression of the steel caused by the cavity pressure

Accessories

Hollow bolt Type 9497A1/9497A2 –

Reamer Type – 1300A79

Socket key AF inside mm 5 5.5

Preload tester Type 5991 5991

Main installation dimensions

Minimum overall depth mm 15.1 39.6

Distance to cavity wall mm 2–3 3–5

Data sheet: see www.kistler.com 9239A (003-403) 9247A (000-143)

Contact-free cavity pressure measurement

h = Minimum overall depth, see table

7.5

13.5

5.5

0.5

7.5

20.3

M5x0.5

ø4.4

.

.

.

M5

x0,5

Ø2,5

+ 0,05 0

min. 19,7

3,5

13,5

3

Ø4,5

+ 0,05 0

min. Ø

5,6

10

M5

x 0,5

Ø2,5

+0,050

min. 15,1

3,5 3

Ø4,5

+0,050

min. Ø

5,6

www.kistler.com10

Increasing numbers of cavities and more complex temperature conditioning concepts: these factors mean that the structure of injection molds is becoming more complicated. But at the same time, molds should be designed so that they are easy to maintain and disassemble. Kistler has consistently responded to these changes with its connection technology for pressure and temperature sensors.

Single-wire and multi-channel cable technologies from Kistler ensure accurate and reliable transmission of the sensor signals to the process monitoring system. In single-wire technology, the cable consists of just one conductor with a very small cross-section. It can be flexibly installed in drilled channels and shortened as required.

Kistler’s single-wire or coaxial technology makes it possible to connect as many as eight different sensors in molds with multiple cavities or with several sensors per cavity. This is a

Connection technology for all installation conditions

space-saving method of connecting them all to the process monitoring system, and it avoids confusion. Signals from combined pressure/temperature measurements can also be transmitted using multi-channel cable technology and a thermocouple amplifier.

For complex and modular molds, contact elements connect cables in different mold elements. Contact surfaces in both elements establish the electrical connection. This greatly simplifies mold installation as compared to conventional connection technology.

Another option is the use of conductive spacer sleeves. If the installation is not angled, the spacer sleeve can be screwed onto the sensor instead of a cable, which greatly simplifies drilling of the installation bore for the sensor. A contact element will be installed on the other side to guarantee secure transmission of the charge.

For every mold concept, Kistler offers the right connection technology – precisely tailored to the installation conditions, the number of cavities and the maintenance requirements.

www.kistler.com 11

Connection technology: cavity pressure sensors

Single-wire connection cables

Coaxial connection cables

Combined pressure/temperature connection cables

Conductive spacer sleeve for single-wire technology

Contact elements for single-wire technology

Illustrated: Type 171420

Illustrated: Type 1645C

Technical data Type 1666A... 1) 1674AZsp 1900A17...

Sensor connection M4 2) M4 2) M3 3)

Length m 1.5/5 0.04 ... 1.5 4) 1.5/5/Zsp 4)

Operating temperature range °C 0 ... 200 0 ... 200 0 ... 200

Color green green green

Technical data Type 1963A... 1955A... 1645C... 1650A... 1900A19L...

Sensor connection M4 2) M4 2) M4 2) M3 3)/M4 2) M3 3)

Plug connection Fischer Fischer Fischer Mini-Coax Fischer

Length m 0.4/sp 5) 0.4/sp 6) 0.2/0.4/0.6/ 0.8/1.0/1.2/ 1.5/1.6/2.0/ 2.5/3.0/sp 6)

0.2/0.4/0.6/ 0.8/1.2/sp 6)

0.2/0.4/0.6/0.8/1.0/1.2/

1.5/sp 6)

Operating temperature range °C 0 ... 200 0 ... 300 0 ... 200 0 ... 200 0 ... 200

Covering Steel-braided

Steel-braided

PFA PFA PFA

Technical data Type 2219B... 2219BG 2219BG1

Sensor connection 6190CA... with connectors

6190CAG without connector for use with Type 2205A...

6190CAG1 without connector for use with Type 2205A...

Length m 0.4/0.8/1.2/1.6/ 2/sp 6)

2 5


Technical data Type 1712C0 1) 1714C0 1)

Number of channels 1 4

Structural dimensions mm M8 × 5.2 (for each element) ø 12 × 9.5 (for each element)

Axial offset during installation mm max. 0.3 max. 0.1

Operating temperature range °C 0 ... 200 0 ... 200

Data sheet: see www.kistler.com 1712C (003-437)

1) Standard product 2) 6159.../6157.../6177.../6167.../6152.../6172.../6162.../6163.../9211.../9213.../9204... 3) 6182.../6183.../9239...A... 4) Custom length (lmin = 0.04 m/lmax = 1.5 m) with crimp contact 5) Custom length (lmin = 0.1 m/lmax = 2 m) 6) Custom length (lmin = 0.1 m/lmax = 5 m)

Technical data Type 1720A1 1720A2

Sensor connection M3 3) M3

Contact element 1712C1 1712C1

Length mm 40 80


www.kistler.com12

Multi-channel technology: cavity pressure sensors

Single-wire sensors for these connectors have extensions G and G1 (example: Type 6157BAG)

Multi-channel connectors for single-wire technology

Extension cable with flexible steel-braided covering

Single-channel technology: cavity pressure sensors

Single-channel connector for single-wire technology

Extension cables: single-channel technology, pressure

Illustrated: Type 1661A...

Technical data Type 1722A... 1) 1708B... 1) 1710B... 1)

Number of channels 4 or 8, with mold identification

4, with mold identifi-cation up to 125°C

8, with mold identifi-cation up to 125°C

Used for sensors All single-wire- and coaxial sensors

All single-wire sensors

All single-wire sensors

Connection Cut-and-grip tech-nology or mini-coax

Cut-and-grip technology

Cut-and-grip technology


Data sheet: see www.kistler.com 1722A (003-264) 1708B (003-138) 1710B (003-138)

Technical data Type 1995A... 1) 1997A... 1)


Length m 1/2/5/sp 2) 1/2/5/sp 2)

Connector (system) 4-channel 8-channel

Connector in mold 4-channel 8-channel


Technical data Type 1839

Used for sensors All single-wire sensors

Connection Cut-and-grip technology

Operating temperature range °C 0 ... 200

Technical data Type 1667B... 1) 1661A... 1672B... 1662A...

Length m 2/5/10/sp 3) 2/5/10/sp 3) 2/5/10/sp 3) 1/2/5/sp 3)

Connector (system) BNC BNC TNC TNC

Connector in mold 1-channel 1-channel 1-channel 1-channel

Operating temperature range °C 0 ... 200 0 ... 200 0 ... 200 0 ... 200

Covering Fluoro-polymer Steel Fluoro-polymer Steel

www.kistler.com 13

Multi-channel technology: cavity pressure sensors

Single-channel technology: cavity pressure sensors

Cable technology: contact temperature sensors

Multi-channel temperature amplifier for temperature sensors without connector

High-temperature extension cables for temperature sensors with connector

Cables are also used for the thermocouple in combined sensors, Types 6189A… and 6190CA… .

Technical data Type 2290A... 2295A...

Length m 2/5/10/sp 4) 2/5/sp 4)

Connector (system) Bare ends 1-channel temperature

Connector in mold 1-channel 1-channel


Technical data Type 2205A...

Measuring range °C 0 ... 200 or 0 ... 400

Thermocouple Type K/J/N

Number of channels 2 or 4

Operating temperature range °C 0 ... 125

Characteristics 2- or 4-channel temperature amplifier for installation in molds for thermocouples, Types K/J/N.

Application Connection of up to 4 pressure/temperature sensors (temperature signal) or 4 temperature sensors to ComoNeo Type 5887A... and CoMo Injection Type 2869B… .

Accessories External housing Type 5700A23, installation support Type 1300A20

Data sheet: see www.kistler.com 2205A (000-591)

1) Standard product 2) Custom length (lmin = 0.3 m/lmax = 20 m) 3) Custom length (lmin = 0.2 m/lmax = 5 m) 4) Custom length (lmin = 0.1 m/lmax = 30 m)

www.kistler.com14

Process monitoring systems from Kistler for cavity pressure-based analysis, optimization, monitoring, documentation and control of injection molding are suitable for every application. Automatic detection and separation of faulty parts mean lower quality costs.

The ComoNeo monitoring system from Kistler offers a host of pioneering innovations that will make everyday injection molding operations far easier.

In addition to process monitoring, various control and regulation modules for injection molding are included in ComoNeo, or can be added.

Process monitoring systems for every application

Kistler offers optimally configured system technology for every quality assurance strategy.

ComoNeo is a compact system, designed to meet industry’s needs; it is based on a process-oriented operating philosophy and fits flexibly into a variety of production environments. The advantage: multiple devices can be networked so that all data can be collected centrally. What’s more, all integrated devices can be reached and configured from every PC – so there is no need to install additional software.

Further system upgrade options are i.e. ComoNeoMULTIFLOW (for automatic hot runner balancing) or ComoDataCenter, the central database.

www.kistler.com 15

Capacitive multi-touch display

ComoNeo process monitoring system

Hardware

Technical data Type 5887A1 5887A2 5887A3 5887A4

Inputs Cavity pressure (connector)

8 (2 × 4-channel)

8 (1 × 8-channel)

16 (2 × 8-channel)

32 (4 × 8-channel)

Automatic choice of measuring range

yes yes yes yes

Voltage Inputs i.e. cavity wall temperature (connector)

8

(1 × 8-channel)

8 (1 × 8-channel)

16

(2 × 8-channel)

16

(2 × 8-channel)

Inputs Machine signals

4 4 4 4

Measuring range Machine signals

V 0 ... ±10 0 ... ±10 0 ... ±10 0 ... ±10

Digital inputs 12 12 12 12

Digital outputs 24 24 24 24

Monitoring boxes 128 128 128 128

Measuring time min ≤40 ≤40 ≤40 ≤40

Dimensions L×H×W 198 × 77 × 148 198 × 77 × 148 198 × 77 × 148 198 × 77 × 148

Sampling rate per channel kHz 16 16 16 16

Operating temperature range

°C 0 ... 50 0 ... 50 0 ... 50 0 ... 50

Degree of protection IP53 IP53 IP53 IP53

Characteristics ComoNeo Type 5887A... is a compact system for data acquisition and process visualization, monitoring and control in injection molding. To visualize the user interface, we recommend the capacitive Multi-touch display, Type 5637A1 (display area: 15.6") that has been specifically designed for ComoNeo.

Application Process analysis, optimization, monitoring and control of the injection molding process. ComoNeo has an internal curve profile history that can store at least 50,000 cycles in the device – these can also be ex-ported via a USB interface.

Accessories ComoDataCenter database, Type 2829D…


Technical data Type 5637A1

Display size 15.6"

Display format 16:9

Characteristics Multi-touch display specially designed to operate ComoNeo. The ComoNeo user interface is optimized for the display format in com-pliance with the latest usability standards and guidelines. Furthermore, the display is fitted with a USB connection so that ComoNeo cycles, data and configurations can easily be exported and imported.

Application Can be connected directly to ComoNeo using the Type 1200A217A … connection cables included in the accessories.


www.kistler.com16


Cable for display, Type 5637A1

Cables for digital signals

Proximity switches

Cable for analog signals

Cable for thermocouple amplifier, Type 2205A …

Supply for ComoNeo

Cables

Illustrated: Type 1457A1A...

Technical data Type 1200A217A...

Length m 2.5/5

Use To connect display, Type 5637A1

Technical data Type 1500B42A... 1) 1500B43A... 1)

Connection Bare ends Bare ends

Length m 0 2)/7/sp 3) 0 2)/7/sp 3)

Use Connection to handling system or scrap gate (digital inputs/outputs, Type 5887A...), 15-pole

Connection to machine signals (digital inputs/outputs, Type 5887A...), 9-pole


Use Trigger (start signal)

Technical data Type 1500B47A...

Connection Bare ends

Length m 0 2)/7/sp 3)

Use To connect analog machine signals, 15-pole

Technical data Type 1491A1A... 1491A2A...

Connection Connector Connector

Length m 2/5/sp 3) 2/5

Use To connect Type 2205A... to 5887A..., 1×4 channels

To connect Type 2205A... to 5887A..., 2×4 channels (Y-cable)


Type Plug-in power supply

Voltage (input) 100 ... 240 VAC

Voltage (output) VDC 24

Connection Mains plug

Use Supply from mains, 100 ... 240 V

1) Standard product 2) Connector only 3) For available lengths, see ComoNeo data sheet 003-231

www.kistler.com 17


Assistance systems

Key characteristics ComoNeoGUARD is a tool that generates and positions the monitoring boxes for good/bad evaluation itself – guiding users quickly and seam-lessly to the scrap limits.

Application By using the Assistant for user-prompted generation of the EO limits, users are guided through the procedure for defining the scrap limits.

Data sheet: see www.kistler.com

Assistance system included in standard scope of delivery. 5887A (000-231)

Key characteristics The Restart module has been integrated into the system since ComoNeo Version 2.0. The purpose of this module is to reproduce the quality of an established injection molding process identically on a new machine.

Application ComoNeoRECOVER makes it possible for users to transfer pre-established processes from one machine to another with no problems at all.


Assistance system included in standard scope of delivery. 5887A (000-231)

ComoNeoGUARD

ComoNeoRECOVER

Add-on products for ComoNeo

www.kistler.com18

Key characteristics ComoNeoSWITCH actively provides machine feedback. This allows ideal timing for the switchover from speed control to pressure control in response to cavity pressure.

Application The automatic switchover control can be used in two different ways. With the first option, setup is manual; with the second, it is fully automatic.


5887A (000-231)

Key characteristics ComoNeoMERGE is especially helpful with the production of multi- component parts. All the cavity pressure data measured in the manu-facturing process is merged to provide a clear visual overview of the complex multi-component injection molding process.

Application In multi-component injection molding processes, multiple mold types are used with different sensor positions.


5887A (000-231)

Key characteristics ComoNeoCOMPOSITE ensures that users can easily recognize the char-acteristic phases of the process such as evacuation, filling and curing in the pressure curve – so process parameters are optimized and pro-duction becomes more cost-efficient.

Application Capture and recording of the pressure signal with ComoNeoCOMPOSITE allows traceability of the individual process steps. The pressure curve is therefore indispensable as a quality assurance tool.


5887A (000-231)

ComoNeoSWITCH

ComoNeoMERGE

ComoNeoCOMPOSITE

ComoNeoMULTIFLOW hot runner balancing, Type 2809A3

Key characteristics Software for automatic optimization of hot runner temperatures. Its purpose: to fill all cavities of a multi-cavity mold synchronously and evenly. Closed control loop based on analysis of cavity pressure curves and automatic determination of the setpoint temperatures, and transfer of this data to the hot runner control device or the injection molding machine. Support for multiple hot runner controllers. See data sheet for details.

Application Automatic balancing of the hot runners of multi-cavity injection molds monitored by ComoNeo Type 5887A... during production startup and series production.

Accessories Ethernet serial converter, Type 2808A2 (hardware)


5887A (000-231)

Process control systems

www.kistler.com 19

ComoNeoPREDICT

Key characteristics Kistler’s online quality prediction is based on models that make it possible to calculate part characteristics.

The statistical DoE test planning process (Design of Experiments) helps determine relationships between pressure / temperature profiles and defined quality features. The result: reliable statements can be made in advance about each manufactured component.

Application When manufacturing injection-molded parts, tolerance limits can be taken directly from the part specifications. Online quality prediction offers particular benefits for manufacturers of sensitive, high-precision parts in the medical technology sector and producers of other critical high-grade components. Finally, online quality prediction opens up the possibility of 100% in-process pre-dictions for all relevant quality characteristics.

For more information: For more information, please contact your Kistler partner directly.

ComoDataCenter Type 2829D...

Key characteristics Database and Curve Viewer to access and analyze process data ac-quired with ComoNeo1).

Data transfer via Ethernet from ComoNeo. Analysis using comfortable user interface. Data export into other systems via open database structure. One standard database is included in the scope of delivery. However, existing databases can also be used.

Application Process analysis, production analysis and efficiency evaluation of all production orders monitored with ComoNeo Type 5887A. Insight into ongoing production, storage, display and analysis of the process and quality information generated by ComoNeo. Analysis based on cycles or trends of significant process values. In addition, there are statistical options for the overall evaluation of production, e.g. machine utilization or efficiency.


2829D (003-175)

1) One license is required for each ComoNeo Type 5887A.

Prediction systems

ComoDataCenter

www.kistler.com20

Kistler offers an extensive range of helpful accessories as well as calibration and testing equipment. For inquiries about our range of accessories, please contact our local distribution partners.

Accessories such as the mounting wrench for mounting nuts or the extraction tool for sensors make it easier to handle and install sensors. The simple way to check your installation: our Sensor Tester for cavity pressure sensors. It can test the sensor’s sensitivity and the insulation for the entire measuring chain.

Handling made simple – our range of accessories

Kistler’s range includes the right accessories for installing the sensor and for verification or testing.

www.kistler.com 21

Tools

Extraction tools for sensors

Mounting wrench for mounting nut

Repair set for single-wire cable

Technical data Type 1315A 1358A 1362A

Outside diameter mm ø 5.8 ø 3.8 ø 5.8

Length mm 150 150 150

Thread Type M5 M3 × 0.35 M5

Sensors Type 6152BA..., 6152BC...,

6157CA..., 6159A...,

6167A..., 6177B...,

6190C..., 6192B...,

6194B..., 9223A... .

6178C..., 6182D...,

6183D..., 6185A...,

6189A..., 6193B...,

6195B... .

6152BB/BD...,

6157CB/CD...,

6190A...

Technical data Type 1383 1356 1363

Outside diameter mm ø 10 ø 5 ø 4.4

Length mm 300 150 60

Sensors Type 6152B..., 6157C...,

6159A..., 6167A...,

6172B..., 6177B...,

6190C..., 6192B...,

6194B...

6178C..., 6182D...,

6183D..., 6185A...,

6193B..., 6195B...

6184A...


Number of repair sets 5

www.kistler.com22

Preload tester

Sensor tester for cavity pressure sensors

Calibration and test equipment


Measuring range pC ±100,000

Output voltage V 0 ... ±1

Description Battery-operated preload tester for charge measurements

Use To measure and test the preload on contact-free measurement sensors. Output for the monitoring function.

Data sheet: see www.kistler.com 5991 (000-340)

Technical data Type 5495C...

For sensors Cavity pressure and temperature sensors

Description Battery-operated handheld tester with test pin and connection cables to test sensor sensitivity, insulation resistance of cables and testing the charge amplifiers

Use Function checks on installed sensors, cables and charge amplifiers

Data sheet: see www.kistler.com 5495 (003-453)

www.kistler.com 23

Adapters for multi-channel technology cavity pressure sensors

Illustrated: Type 5415A1

Illustrated: Type 5415A3

Adapter boxes: single-channel technology to multi-channel technology

Adapter boxes for multi-channel technology

Adapter cables: multi-channel technology to single-channel technology



Connector (system) 4-channel 8-channel

Connector in mold 4 × 1-channel BNC 8 × 1-channel BNC




Connector (system) 8-channel 2 × 4-channel

Connector in mold 2 × 4-channel 8-channel


Technical data Type 1991A... 1999A1A0.5 1999A2A0.5

Number of channels 1 4 8

Length m 2/5/sp 1) 0.5 0.5

Connector (system) 4-channel 4 × BNC 8 × BNC

Connector in mold 1-channel 4-channel 8-channel


1) Custom length (lmin = 0.3 m/lmax = 20 m)

www.kistler.com24

Kistler offers sales and service wherever plastics processors manufacture high-grade injection molded parts.

In addition to sensors and systems, Kistler offers a host of services – from professional advice on installation to speedy worldwide deliveries of spare parts. For an overview of the services we offer, visit www.kistler.com. For detailed information on our training courses, please contact our local distribution partners (see page 26).

No matter what your assembly problem looks like – we have the right solution for you. Eight typical examples taken from practice are shown on the next page.

Kistler service: customized solutions from A to Z

From professional advice on installation to speedy deliveries of spare parts: Kistler’s comprehensive range of services and training is at your disposal across the globe.

Kistler service at a glance: • Consulting • Support with system commissioning • Process optimization • Periodic calibration of sensors used at customers’ sites • Education and training events • Development services

www.kistler.com 25

Installation examples

2

3

4

5

6

7

1

1

9

10

8

1 1

2

2

2

2 2

3

3

3

3 3

4

4

5

1

1 1

11

8 8

8

9

99

1

6

7

10

Protective tube

Contact element

Spacer sleeve

Mounting nut

Conductive spacer sleeve

Keyway pin

Sensor

Sensor

Thrust washer

Measurement pin

Ejector pin

Installation with spacer sleeve and contact elements, cable with protective tube

Installation with conductive spacer sleeve and contact element, cable with protective tube

Mounted behind ejector pin in supporting plate

Mounted behind measurement pin in blind hole with thrust washer

Installation with mounting nut and contact elements, cable with protective tube

Sensor with machinable front and keyway pin, installation with spacer sleeve

Mounted behind ejector pin in blind hole with thrust washer

Sensor installed with play, mounted behind ejector pin in blind hole with thrust washer

www.kistler.com26

Thanks to Kistler’s global sales and service network, we are always close to our customers. Approximately 2,000 employees at 61 locations are dedicated to the development of new measurement solutions and offer customized on-site support of individual applications.

At our customers’ service across the globe

Education and training eventsEducation and training courses, during which our sensors and measuring systems are explained by Kistler experts, are the most efficient way for you to obtain the required user knowledge.

Our representatives are here to helpWhether you would like a consultation or require support during installation – our website provides the contact information for your local representative.

Data sheets and documentsUse our Online Search to download data sheets, brochures or CAD data.

www.kistler.com 27

Sales Center Tech Center Production Center

SindelfingenNovi Shanghai YokohamaHeadquarters, Winterthur

Thanks to Kistler’s global sales and service network, we are always close to our customers. Approximately 2,000 employees at 61 locations are dedicated to the development of new measurement solutions and offer customized on-site support of individual applications.

At our customers’ service across the globe

Education and training eventsEducation and training courses, during which our sensors and measuring systems are explained by Kistler experts, are the most efficient way for you to obtain the required user knowledge.

Our representatives are here to helpWhether you would like a consultation or require support during installation – our website provides the contact information for your local representative.

Data sheets and documentsUse our Online Search to download data sheets, brochures or CAD data.

960-

112e

-05.20

© 2

020

Kis

tler

Gro

up

Find out more about our applications: www.kistler.com/applications

Kistler Group Eulachstrasse 22 8408 Winterthur Switzerland Tel. +41 52 224 11 11

Kistler Group products are protected by various intellectual property rights. For more details, visit www.kistler.com The Kistler Group includes Kistler Holding AG and all its subsidiaries in Europe, Asia, the Americas and Australia.

Find your local contact at www.kistler.com

Documents

Sensors and systems - Kistler